EP4070946A1 - Schichtverbundstoff - Google Patents

Schichtverbundstoff Download PDF

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Publication number
EP4070946A1
EP4070946A1 EP20896177.1A EP20896177A EP4070946A1 EP 4070946 A1 EP4070946 A1 EP 4070946A1 EP 20896177 A EP20896177 A EP 20896177A EP 4070946 A1 EP4070946 A1 EP 4070946A1
Authority
EP
European Patent Office
Prior art keywords
steel plate
layered composite
fiber
carbon
layered
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20896177.1A
Other languages
English (en)
French (fr)
Other versions
EP4070946A4 (de
Inventor
Hiroki Yanaga
Hirofumi Tashiro
Hideki Yamagata
Keisuke Sone
Masaki Kobayashi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyo Kohan Co Ltd
Suncorona Oda Co Ltd
Original Assignee
Toyo Kohan Co Ltd
Suncorona Oda Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toyo Kohan Co Ltd, Suncorona Oda Co Ltd filed Critical Toyo Kohan Co Ltd
Publication of EP4070946A1 publication Critical patent/EP4070946A1/de
Publication of EP4070946A4 publication Critical patent/EP4070946A4/de
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • B29C70/14—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat oriented
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
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    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
    • B29C70/885—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding with incorporated metallic wires, nets, films or plates
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    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/243—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using carbon fibres
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Definitions

  • the present invention relates to a layered composite of a carbon-fiber-reinforced resin and metal.
  • a carbon-fiber-reinforced resin is used as automobile members and housings of electronic apparatuses.
  • Such a carbon-fiber-reinforced resin has both high strength and high moldability, and a molded body is manufactured by a mold pressing method, an autoclave method, and the like.
  • PTL 1 discloses a carbon-fiber-reinforced resin exhibiting isotropic properties which is manufactured by disposing prepregs in a manner of layering the prepregs at random and by heating and processing the prepregs.
  • a carbon-fiber-reinforced resin typically has such characteristics that molding in a short period of time is possible, secondary processing is possible, or recycle can easily be performed. Owing to these characteristics, the carbon-fiber-reinforced resin has come into attention to be used as automobile and electronic apparatus members which are relatively low in cost, large in the number of production, and demanded to have complicated shapes.
  • the carbon-fiber-reinforced resin described in PTL 1 is one having both strength and moldability, but a problem is yet to be solved in terms of elastic modulus which is another important parameter.
  • the carbon-fiber-reinforced resin using cut fibers as described in PTL 1 itself has certain degrees of strength and moldability, but when the carbon-fiber-reinforced resin is used alone, it has been difficult to largely enhance the elastic modulus while maintaining isotropic properties.
  • the carbon-fiber-reinforced resin which does not have isotropic properties such as a continuous fiber has a problem in terms of moldability in that complicated molding is impossible in the first place.
  • PTL 2 to PTL 6 disclose technologies in which a metallic material such as steel plate or aluminum and a fiber-reinforced resin are layered through or not through an adhesive.
  • a composite material in which metal and a fiber-reinforced resin are joined for the purpose of enhancing specific rigidity and specific strength or lightening and enhancing strength.
  • a layered composite including a carbon-fiber-reinforced resin having isotropic properties in which carbon fibers are impregnated with a thermoplastic resin and a metallic material (steel plate) layered on at least one surface of the carbon-fiber-reinforced resin, a layered composite having a high flexural modulus and a molded body having a high flexural modulus by use of the layered composite.
  • a layered composite of the present embodiment is (1) a layered composite including a carbon-fiber-reinforced resin in which a chopped strand prepreg obtained by impregnating carbon fiber in resin is oriented and layered in such a manner as to exhibit pseudo-isotropic properties, and a steel plate that is layered on at least one surface of the carbon-fiber-reinforced resin and has a tensile breakage elongation ⁇ of equal to or more than 20%, in which the flexural modulus in a flat plate state obtained in compliance with American Society for Testing and Materials (ASTM) D-790 is equal to or more than 30 GPa, and, in evaluation of moldability of the layered composite in an element type illustrated in an example, at least one of a wrinkle, breakage, and a gap at a layered interface is not generated in the steel plate when molding is conducted with a punch shoulder radius of 0 ⁇ R ⁇ 2.
  • a layered composite of the present embodiment includes (2) a carbon-fiber-reinforced resin in which a chopped strand prepreg obtained by impregnating carbon fiber in resin is oriented in such a manner as to exhibit pseudo-isotropic properties, and a steel plate that is layered on at least one surface of the carbon-fiber-reinforced resin and has a tensile breakage elongation ⁇ of equal to or more than 20%, in which the flexural modulus in a flat plate state obtained in compliance with ASTM D-790 is equal to or more than 30 GPa.
  • a wrinkle, breakage, and a gap at the layered interface is preferably not generated in the steel plate when molding is conducted with a punch shoulder radius of 0 ⁇ R ⁇ 2.
  • the ratio of the thickness of the steel plate to the total thickness of the layered composite be 1% to 20%.
  • a specific flexural modulus of the layered composite be equal to or more than 20 but equal to or less than 25.
  • the steel plate be a surface treated steel plate, and the surface treatment be plating including Zn or Ni.
  • a molded body of the present embodiment is (8) a molded body molded by the layered composite according to any one of (1) to (7) above, characterized by having a shoulder part with a shoulder radius of 0 ⁇ R ⁇ 2.
  • a layered composite having a high flexural modulus and a molded body, in a composite material in which a steel plate and a carbon-fiber-reinforced resin are layered.
  • FIG. 1 is a diagram schematically depicting a layered composite according to the present embodiment.
  • a layered composite 10 of the present embodiment is used for an automobile member, an electronic apparatus member, or the like.
  • the layered composite 10 of the present embodiment may be used in a flat plate state, or may be subjected to such molding as press molding under heating and/or pressure.
  • the layered composite 10 of the present embodiment includes a carbon-fiber-reinforced resin 110 and a steel plate 120 layered on at least one surface of the carbon-fiber-reinforced resin 110.
  • the steel plate 120 is layered on one side of the carbon-fiber-reinforced resin 110 to constitute a two-layer structure, but the present invention is not limited to this.
  • the steel plates 120 may be layered on both sides of the carbon-fiber-reinforced resin 110 to constitute a three-layer structure.
  • the carbon-fiber-reinforced resins 110 and the steel plates 120 may alternately be layered to constitute a multilayer structure.
  • the layered composite 10 of the present embodiment is characterized by a flexural modulus of equal to or more than 30 GPa in a flat plate state. The reason is as follows.
  • an electronic apparatus housing for protecting a precision part enhancement of both thinning and rigidity is demanded.
  • the housing is formed from only resin, it is necessary to increase the material thickness to enhance rigidity, but layering metal makes it possible to enhance rigidity of the layered body as a whole without increasing the material thickness of the resin part.
  • an upper limit of the housing thickness is often determined for the housing of a personal computer (PC) or the like, it is an advantage that rigidity as a whole can be enhanced without increasing the material thickness of the resin.
  • one method of enhancing the rigidity is to enhance the flexural modulus of the material.
  • the present inventors in order to enhance the flexural modulus to some extent also in a molded body by secondary processing, repeatedly made studies for enhancing flexural modulus even in a state of being in a flat plate before molding.
  • the present inventors found out that, when the carbon-fiber-reinforced reason and the steel plate are layered on each other to constitute a layered composite, in a flat plate state, the flexural modulus can be enhanced as compared to the case where the layered composite includes the carbon-fiber-reinforced resin alone. Further, the present inventors also found out that, in the case where the molded body is manufactured by secondary processing, lowering in flexural modulus cannot be avoided as compared to a flat plate, but the flexural modulus can be enhanced as compared to the case where the layered composite includes the carbon-fiber-reinforced resin alone, thereby arriving at the present invention.
  • the flexural modulus of the molded body can be made to be equal to or more than a predetermined value.
  • the value of the flexural modulus of the present embodiment can be obtained in compliance with ASTM D-790.
  • the specific flexural modulus is preferably equal to or more than 20, from the same point of view as described above.
  • the specific flexural modulus is a value obtained by dividing the flexural modulus obtained as described above by the specific gravity of the layered composite 10.
  • the thickness of the layered composite 10 of the present embodiment is not particularly limited to any value, and is appropriately modified according to use.
  • the thickness is preferably on the order of 0.3 to 3.0 mm from the viewpoint of physical properties and moldability.
  • a carbon-fiber-reinforced resin 110 used for the layered composite 10 of the present embodiment will be described.
  • the carbon-fiber-reinforced resin 110 applied is a carbon-fiber-reinforced resin in which a chopped strand prepreg including carbon fiber tow impregnated with resin is oriented in such a manner as to exhibit pseudo-isotropic properties is applied.
  • the carbon fiber tow specifically used may be a pitch type carbon fiber or may be a polyacrylonitrile (PAN) type carbon fiber, but is preferably the PAN type carbon fiber from the viewpoint of handleability.
  • the filament diameter of one carbon fiber is normally 5 to 8 ⁇ m, and a fiber bundle in which a plurality of carbon fibers are collected in a flat form in a predetermined filament number is preferably used.
  • the filament number of the carbon fibers is 3,000 to 600,000 from the viewpoint of productivity of the prepreg manufacture, more preferably 6,000 to 24,000.
  • the carbon fiber may be used alone, or may be used in combination with reinforcing fibers other than a carbon fiber. Examples of the reinforcing fiber which can be used in combination include known fibers such as an aramid fiber, a polyethylene fiber, a glass fiber, metallic fiber, and a natural fiber.
  • the carbon fiber used for the layered composite 10 of the present embodiment is preferably spread from the viewpoint of enhancing penetration of the matrix resin at the time of manufacturing the prepreg, and, in the case of using a reinforcing fiber other than the carbon fiber in combination, the reinforcing fiber other than the carbon fiber is also preferably spread
  • thermoplastic resin a known thermoplastic resin used as a matrix of a fiber-reinforced resin can be applied.
  • an in-situ polymerization type thermoplastic epoxy resin is preferably used, and the use of a bisphenol A type epoxy resin is particularly preferable from the viewpoint of high penetration to fibers at the time of prepreg manufacture and adhesion to the steel plate used in the present embodiment.
  • the carbon-fiber-reinforced resin 110 used in the present embodiment can be obtained as follows.
  • a uni-directional prepreg for example, uni-directional (UD) tape
  • a predetermined length chopped strand prepreg
  • a thermoplastic resin is layered by being scattered at random, is then heated to soften the resin and fix the tape pieces together, whereby the carbon-fiber-reinforced resin 110 of the present embodiment can be obtained.
  • the carbon-fiber-reinforced resin 110 can be obtained.
  • the uni-directional prepreg used for the carbon-fiber-reinforced resin 110 of the present embodiment use of a uni-directional prepreg including carbon fiber tow impregnated with a thermoplastic resin without any void (bubbles or the like) being contained between fibers is preferable at prepreg manufacture. This makes it possible to enhance the close contact properties of the uni-directional prepreg in the carbon-fiber-reinforced resin 110 obtained, and further enhance the strength and isotropic properties of physical properties of the layered composite 10.
  • the fiber volume content Vf of the uni-directional prepreg is preferably controlled to be 30% to 55%, more preferably 35% to 45%.
  • the abovementioned range is preferable from the viewpoint of enhancing moldability of the molded body.
  • the volume content exceeds the upper limit, a non-impregnated part of the prepreg is increased, making it difficult to make the prepreg voidless, which is unfavorable.
  • the volume content is below the lower limit, it is difficult to secure strength of the layered composite 10, which is unfavorable.
  • an average length in the fiber direction of the uni-directional prepreg is 10 to 50 mm, preferably 10 to 30 mm.
  • the carbon-fiber-reinforced resin 110 comes to exhibit pseudo-isotropic properties, and the moldability of the layered composite 10 obtained as a result can be enhanced.
  • the uni-directional prepreg in the tape form for example, the one disclosed in PTL 1 can be used.
  • the thickness of the carbon-fiber-reinforced resin 110 in the present embodiment is not particularly limited to any value, but, for example, is preferable to be on the order of 0.1 to 2.0 mm from the viewpoint of weight saving.
  • the thickness of the carbon-fiber-reinforced resin may appropriately be modified according to the shape of the molded body.
  • the flexural modulus Gc of the carbon-fiber-reinforced resin 110 in the present embodiment is preferably equal to or more than 20 GPa, in light of the flexural modulus required of the layered composite 10.
  • the steel plate 120 in the present embodiment may be layered at least on one side of the carbon-fiber-reinforced resin 110, or may be layered on both sides of the carbon-fiber-reinforced resin 110 though not illustrated, or the steel plate 120 and the carbon-fiber-reinforced resin 110 may alternately be layered in multilayer.
  • Examples of the steel plate 120 used for the layered composite 10 of the present embodiment include a known steel plate.
  • a hot rolled steel plate obtained by hot rolling an aluminum-killed continuous cast steel and removing the scale formed on the surface, or a cold rolled steel plate obtained by cold rolling a hot rolled steel plate and annealing the cold rolled steel plate is applicable.
  • the steel plate 120 to be used in the present embodiment is preferably a surface treated steel plate from the viewpoint of close contact properties (restraint of gap at layered interface) with the carbon-fiber-reinforced resin 110 and control of frictional coefficient, particularly, enhancement of moldability by reduction of frictional coefficient, corrosion resistance, and the like.
  • the surface treatment includes plating, chemical conversion treatment, resin coating, or surface roughening, each of which can be used preferably.
  • a plated steel plate for example, a plated steel plate provided with a monolayer plating of any of Sn, Ni, Co, Mo, Zn, and Cr or a multilayer plating or an alloy plating (compound plating) of two or more kinds can be used.
  • a Zn plated steel plate or an Ni plated steel plate is preferable.
  • the Zn plating includes Zn alloy plating
  • the Ni plating includes Ni alloy plating.
  • resin coating for example, known polyester resin, urethane resin, acrylic resin, and the like can be mentioned.
  • the interface side with respect to the carbon-fiber-reinforced resin 110 of the steel plate 120 is preferably roughened.
  • the other surface (opposite side) which is an outer side may be flat without being roughened from the viewpoint of reduction of frictional coefficient, design, and the like.
  • the steel plate 120 of the present embodiment is characterized by a tensile breakage elongation ( ⁇ ) of equal to or more than 20%.
  • the layered composite 10 of the present embodiment as described above, is characterized by having both flexural modulus and moldability at high levels in a flat plate state.
  • the flexural modulus of the layered composite 10 in the flat plate state is equal to or more than 30 GPa, whereby flexural modulus and moldability are both secured at high levels.
  • the thickness (plate thickness t) of the steel plate 120 of the present embodiment is preferably on the order of 0.05 to 2.0 mm, depending on the use of the layered composite 10 obtained, and particularly preferably in the range of 0.05 to 0.50 mm.
  • the steel plate 120 having a thickness less than 0.05 mm is unfavorable in terms of manufacture and handleability.
  • the steel plate 120 having a thickness exceeding 2.0 mm makes it difficult to achieve the purpose of weight saving in the final molded body or the like.
  • the thickness ratio of the steel plate 120 to the total thickness of the layered composite 10 is preferably 1% to 50%, and, further, is particularly preferably 1% to 20% from the viewpoint of securing weight saving, strength, flexural modulus, and the like at high levels.
  • the steel plate 120 of the present embodiment preferably has, in the case where the frictional coefficient at its surface (a surface making contact with a mold) is ⁇ , a parameter S represented by the following calculation formula (1) of equal to or more than 7.5.
  • S plate thickness t of steel plate ⁇ tensile breakage elongation ⁇ / frictional coefficient ⁇ of steel plate
  • the flexural modulus of the carbon-fiber-reinforced resin 110 should be reinforced by the steel plate 120; in the case where the above parameter S is equal to or more than 7.5, favorable moldability of the layered composite 10 can be obtained. In the case where the parameter S is equal to or more than 20, a further preferable result can be obtained in terms of moldability.
  • the frictional coefficient ⁇ of the steel plate in the calculation formula (1) can be measured by a known frictional coefficient measuring device.
  • the frictional coefficient can be measured by a Tribogear surface property measuring device (TYPE: 14FW) made by SHINTO Scientific Co., Ltd.
  • TYPE Tribogear surface property measuring device
  • the frictional coefficient ⁇ can be varied according to the finish surface roughness of the steel plate, surface treatment, or the like. For example, by lowering the frictional coefficient of the steel plate making contact with the mold surface at the time of manufacture of the molded body, it becomes easy for the steel plate to enter the mold, and breakage or a wrinkle is not easily generated in the steel plate that has been subjected to molding.
  • a mold for a layered composite in a flat plate form is heated to 180°C at 5°C /min. After the mold temperature reaches 180°C, the carbon-fiber-reinforced resin 110 and the steel plate 120 are put into the mold, and are kept, for example, at 180°C and 0.5 MPa for 3 minutes. Next, for example, the carbon-fiber-reinforced resin 110 and the steel plate 120 are pressed at 180°C and 4 MPa for 12 minutes, and are then subjected to natural cooling. Then, when the mold temperature becomes 70°C or below, load is removed (pressing is cancelled), whereby the layered composite 10 of the present embodiment can be obtained.
  • the manufacturing method for the layered composite 10 in the flat plate form is not limited to the one under the above manufacturing conditions.
  • a known manufacturing method can be applied insofar as the characteristics of the layered composite 10 are provided.
  • a method of extruding the melted carbon-fiber-reinforced resin 110 onto the steel plate 120 and a method of laminating a thermal adhesion film on the steel plate 120 followed by thermocompression bonding of the steel plate 120 with the thermal adhesion film and the carbon-fiber-reinforced resin 110 to form the layered composite 10 are applicable.
  • the molded body 20 in the present embodiment is characterized by being molded by the abovementioned layered composite 10.
  • the abovementioned layered composite 10 for example, when a molded body is manufactured by application of press molding or the like under heating and/or pressurizing by a press molding method, even in the case where a mold with a relatively small R at a corner part is used, generation of at least one of a wrinkle, breakage, and a gap at a layered interface in the molded body can be restrained.
  • FIG. 2 depicts an example of a mold MD as a mold for manufacturing the molded body 20 of the present embodiment.
  • FIG. 2 is a front view of the mold MD used for manufacturing the molded body 20 of the present embodiment.
  • the mold MD has a shoulder part having a plurality of punch shoulder radii R.
  • FIG. 3(a) is an enlarged view of a shoulder part A in FIG. 2
  • FIG. 3(b) is an enlarged view of a shoulder part B in FIG. 2
  • FIG. 3(c) is an enlarged view, as viewed from a lateral side, of a shoulder part C in FIG. 2 .
  • the shoulder part A of the mold MD is continuous at R2
  • the shoulder part B is continuous at R10
  • the shoulder part B is continuous at R2 and R7, and, therefore, the mold MD includes a shoulder part having a plurality of shoulder radii.
  • the molded body 20 of the present embodiment is molded from the abovementioned layered composite 10 by use of the abovementioned mold MD, the molded body 20 is characterized by having a shoulder part with a punch shoulder radius of 0 ⁇ R ⁇ 2.
  • this molded body is preferably manufactured by one-time press molding.
  • the molded body 20 of the present embodiment preferably has a plurality of punch shoulder radii as depicted in FIGS. 2 and 3 .
  • the layered composite 10 of the present embodiment is characterized in that a tensile breakage elongation ⁇ of the steel plate 120 is equal to or more than 20% and that a flexural modulus is equal to or more than 30 GPa in a flat plate state.
  • a tensile breakage elongation ⁇ of the steel plate 120 is equal to or more than 20% and that a flexural modulus is equal to or more than 30 GPa in a flat plate state.
  • a mold having a shoulder part with a small shoulder radius R such as the mold MD depicted in FIGS. 2 and 3
  • either the gap between the carbon-fiber-reinforced resin 110 and the steel plate 120 or a wrinkle or breakage of the steel plate 120 is restrained, and rigidity of the layered composite can be enhanced without the thickness of the resin part being increased.
  • the mold preferable for the present embodiment is not limited to the ones depicted in FIGS. 2 and 3 , and a mold having a shoulder part with a shoulder radius of 0 ⁇ R ⁇ 2 can naturally be applied to the manufacture of the molded body 20 of the present embodiment.
  • a method of molding the abovementioned layered composite 10 by press molding with use of a mold having a shoulder part with a shoulder radius of 0 ⁇ R ⁇ 2 is applicable.
  • a method of molding the abovementioned carbon-fiber-reinforced resin 110 and the steel plate 120 by press molding with use of a mold having a shoulder part with a shoulder radius of 0 ⁇ R ⁇ 2 is applicable.
  • a mold for the molded body 20 is heated to 200°C at 10°C /min. After the mold temperature reaches 200°C, the carbon-fiber-reinforced resin 110 and the steel plate 120 are put into the mold, and are kept at 200°C and 0.5 MPa for 1 minute. Next, the carbon-fiber-reinforced resin 110 and the steel plate 120 are pressed at 200°C and 10 MPa for 5 minutes, and then subjected to natural cooling. When the mold temperature becomes 70°C or below, load is removed, whereby the molded body 20 can be obtained.
  • the method of manufacturing the molded body 20 is not limited to the one under the above manufacturing conditions, and a known manufacturing method can be applied insofar as the characteristics of the abovementioned molded body 20 are provided.
  • the layered composite 10 and the molded body 20 may be manufactured separately.
  • the carbon-fiber-reinforced resin 110 and the steel plate 120 are put into the same mold to manufacture the layered composite 10, and thereafter the molded body 20 may be formed as secondary processing.
  • carbon fiber thread PYROFIL TR50S15L: made by Mitsubishi Chemical Corporation
  • a spread tape was formed by use of a known spreading device.
  • a heat melted thermoplastic epoxy resin XNR/H6850V: made by Nagase ChemteX Corporation
  • the obtained spread tape was impregnated with the resin composition, and was thereafter heated and solidified, to obtain a tape form uni-directional prepreg (fiber volume content (Vf): 40% ⁇ 2%).
  • the obtained tape form uni-directional prepreg was cut to a length of 13 mm, to obtain a chopped strand prepreg.
  • the chopped strand prepreg was scattered and layered in a mold such that the fiber direction was at random (pseudo-isotropic properties). Then heating at 150°C for 1 minute 30 seconds was conducted to soften the resin contained in the chopped strand prepreg and to fix the tape pieces, thereby obtaining a carbon-fiber-reinforced resin (thickness: 1.9 mm).
  • a cold rolled steel plate having a thickness of 0.1 mm was subjected to an alkali electrolytic degreasing treatment and a sulfuric acid pickling treatment by ordinary methods.
  • Tensile modulus, tensile breakage elongation (elongation) (%), specific gravity, frictional coefficient, and the parameter S obtained by the abovementioned calculation formula are as set forth in Table 1.
  • a mold MD depicted in FIG. 2 was prepared.
  • This mold MD has a plurality of corner parts, which have R values of R2, R7, and R10.
  • the layered composite obtained above was placed in the mold MD heated to 200°C.
  • the outer surface of the projected shape of the molded body was made to be the steel plate.
  • the flexural modulus was evaluated as follows.
  • the average flexural modulus of the layered composite was measured in compliance with ASTM D-790 by use of a precision universal testing machine (autograph AG-100kNXplus) made by SHIMADZU CORPORATION. Specifically, from the obtained flat plate form layered composite (flat plate), a rectangular specimen of a length of 80 ⁇ 1.0 mm and a width of 25 ⁇ 0.2 mm in any length direction was cut out, and was used as a measurement specimen. Similarly, a total of 10 measurement specimens were prepared. For each of the measurement specimens, a span of 64 mm and a test speed of 3.4 mm/min were applied to measure the flexural modulus, with a probe side on five steel surfaces and five carbon surfaces.
  • the average value of the flexural modulus for the 10 measurement specimens was set forth as the average flexural modulus in Table 2.
  • the specific flexural modulus was also set forth in Table 2. Note that the case where the average flexural modulus is equal to or more than 30 could be determined as being favorable.
  • the evaluation of moldability of the molded body manufactured by the layered composite obtained above was evaluated as follows. Specifically, in regard of the throttle surface of a corner part and a central part of the molded body obtained, (a) whether or not breakage of the steel plate is present, (b) whether or not a wrinkle is generated on the surface of the steel plate, and (3) whether or not a gap is generated at the layered surface of the carbon-fiber-reinforced resin and the steel plate, were visually observed. As a result of observation, evaluation was made with Excellent, Good, and Poor as set forth below, and set forth in Table 2.
  • each of the carbon-fiber-reinforced resin and the steel plate was set as set forth in Table 1.
  • the annealing conditions of the steel plate were changed to set the elongation as set forth in Table 1.
  • the frictional coefficient is also set forth in Table 1.
  • Other factors were similar to those in Example 1.
  • the results are set forth in Table 2.
  • each of the carbon-fiber-reinforced resin and the steel plate was set as set forth in Table 1.
  • the annealing conditions of the steel plate were changed to set the elongation as set forth in Table 1.
  • the frictional coefficient is also set forth in Table 1.
  • Other factors were similar to those in Example 1.
  • the results are set forth in Table 2.
  • the annealing conditions of the steel plate were changed to set the elongation as set forth in Table 1.
  • the frictional coefficient is also set forth in Table 1.
  • a steel plate a surface treated steel plate subjected to compound Zn plating including Zn-Co-Mo and a phosphate system chemical conversion treatment were used. Other factors were similar to those in Example 2. The results are set forth in Table 2.
  • the annealing conditions of the steel plate were changed to set the elongation as set forth in Table 1.
  • the frictional coefficient is also set forth in Table 1.
  • a steel plate a surface treated steel plate subjected to compound Zn plating including Zn-Co-Mo, a vanadium system chemical conversion treatment, and a urethane resin coating were used. Other factors were similar to those in Example 2. The results are set forth in Table 2.
  • the annealing conditions of the steel plate were changed to set the elongation as set forth in Table 1.
  • the frictional coefficient is also set forth in Table 1.
  • surface treated steel plates subjected to compound Zn plating including Zn-Co-Mo, a vanadium system chemical conversion treatment, and an olefin-modified acrylic resin coating were used. Other factors were similar to those in Example 2. The results are set forth in Table 2.
  • a thermal adhesion film was thermally laminated to produce a thermal adhesion film steel plate.
  • the thermal adhesion film steel plate and the carbon-fiber-reinforced resin were thermocompression bonded to each other to obtain a layered composite.
  • the thus obtained layered composite was pressed at 180°C and 4 MPa for 12 minutes. After cooling down to 70°C, load is removed, and the layered composite was taken out, to obtain the layered composite.
  • Other factors are similar to those in Example 2. The results are set forth in Table 2.
  • the annealing conditions of the steel plate were changed to set the elongation as set forth in Table 1.
  • the frictional coefficient is also set forth in Table 1.
  • Other factors were similar to those in Example 2.
  • the results are set forth in Table 2.
  • Example 2 The example was carried out in a manner similar to that of Example 1 except that the thickness of the carbon-fiber-reinforced resin was 2.0 mm and the steel plate was not used. The results are illustrated in Table 2.
  • the carbon-fiber-reinforced resin was a carbon fiber texture impregnated with a thermoplastic polypropylene resin.
  • the thickness and the fiber volume content (Vf) were as set forth in Table 1. Other factors were similar to those in Example 2. The results are set forth in Table 2.
  • the annealing conditions of the steel plate were changed to set the elongation as set forth in Table 1.
  • the frictional coefficient is also set forth in Table 1.
  • Other factors were similar to those in Example 2.
  • the results are set forth in Table 2.
  • the annealing conditions of the steel plate were changed to set the elongation as set forth in Table 1.
  • the frictional coefficient is also set forth in Table 1.
  • Other factors are similar to those in Example 2.
  • the results are set forth in Table 2.
  • the embodiment and each Example can variously be modified within such a range as not to depart from the gist of the present invention.
  • the layered composite and the molded body using the layered composite in the Embodiment and Examples have mainly been described to be used as automobile member or housing of electronic apparatus, but these uses are not limitative and other uses such as heat radiators and electromagnetic shielding materials are applicable.
  • the layered composite and the molded body using the layered composite of the present invention are applicable to wide industrial field such as automobiles and electronic apparatuses.

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